Method for Packaging a Beverage Powder in a Beverage Capsule

ABSTRACT

A method for packaging in a capsule a beverage powder tending to evolve a gas, said capsule comprising a capsule body ( 103 ) defining a cavity ( 106 ) containing a quantity of beverage powder, said cavity being hermetically sealed up comprises the following steps:
         providing a quantity of said beverage powder evolving a gas within said cavity ( 106 ) of said capsule body ( 103 );   applying a vacuum into said cavity ( 106 ) of the capsule body ( 103 ), so that the internal pressure in the cavity ( 106 ) is below atmospheric pressure;   sealing the capsule to hermetically close said cavity ( 106 ), while maintaining the internal pressure in the cavity ( 106 ), below atmospheric pressure; and   keeping said gas emanating into the cavity ( 106 ) of the capsule so that the internal pressure in the sealed-up capsule is above atmospheric pressure.       

     Use for packaging in a capsule a ground coffee.

CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCESTATEMENT

This application is a US national stage application filed under 35 USC§371 of International Application No. PCT/EP2013/063175, filed Jun. 25,2013; which claims benefit of EP Application No. 12174911.3, filed Jul.4, 2012. The entire contents of the above-referenced applications arehereby expressly incorporated herein by reference.

FIELD OF THE INVENTION

The presently disclosed and/or claimed inventive concept(s) relatesgenerally to a method for packaging a beverage powder tending to evolvea gas in a beverage capsule. It also relates to a beverage capsule soproduced. In particular, the presently disclosed and/or claimedinventive concept(s) relates to such capsules as adapted for coffeebeverages.

BACKGROUND

Coffee beans, before being used to prepare a coffee beverage, mustgenerally be roasted. This process induces numerous chemical reactionsand physical changes within the coffee beans, which must be accountedfor when packaging the roasted coffee.

The roasting process is what produces the characteristic flavor ofcoffee by causing the green coffee beans to expand and to change incolor, aroma and density. The oils and aromatic volatiles containedand/or developed during roasting confer the aroma and flavor of thecoffee beverage produced therefrom, but are also prone to degradationwhen exposed to the oxygen in the surrounding air. It is thus importantto protect the roasted coffee from the surrounding air, to maintainoptimal freshness and shelf life. The roasting process also causes theproduction of gases within the coffee beans, primarily carbon dioxideand carbon monoxide. These gases are slowly evolved by the coffeesubsequent to roasting in a process called “degassing.” Grinding theroasted coffee beans will accelerate this process.

Recently, it has been common to base beverage production systems on theprinciple of portioned beverages; that is, providing a pre-determinedvolume of a beverage upon demand. This has been typically accomplishedby providing a capsule, which contains a pre-portioned amount of abeverage powder, most commonly ground coffee. Hot water is thenintroduced into the capsule to prepare the beverage, which is thendispensed into a container for consumption. Before use, the capsule canbe hermetically sealed under vacuum or controlled atmosphere such asmentioned in WO8602537 to reduce oxidation by the contact of coffee withair. While this specification refers to a “capsule,” it is understoodthose other terms, such as “pod,” “cartridge,” or “packet” may beemployed instead.

Such capsules may be configured so as to be hermetically sealed up untiluse. It is evident that by such hermetical sealing, it is meant that agas transfer is not made possible in any direction between the inside ofthe capsule and the external atmosphere at least for many months. Thisis desirable, as the capsule will prevent the essential oils present inthe coffee from degradation caused by contact with oxygen in the air.This improves the flavor and shelf life of the coffee within such acapsule. It is also evident that due to its hermetical closure, thecapsule is configured for a single use.

However, as described above, coffee will evolve gas after roasting. Whenthe ground coffee is packaged in a sealed container, the container willtrap any gases evolved by the coffee contained within, which in somecases may cause the container to rupture under the pressure generated bythe evolved gas. The container must be constructed more robustly,requiring more materials for its construction and increasing the cost ofits fabrication.

To avoid this, the coffee is held aside for a period of time, allowingsubstantially all of the gases to be released from the coffee before itis packaged in containers. This process is known in the art as“degassing.” By degassing the coffee beforehand, one may avoid theevolution of gas within the sealed container and the accompanyingaccumulation of pressure.

However, the step of degassing beforehand coffee causes a loss ofaromatic compounds. This aroma loss reduces the aroma intensity andmodifies the aromatic profile of the final beverage obtained from theextraction of the beverage capsule.

The degassing process is generally accomplished by the use of degassingsilos or buffers, within which the coffee is stored while it degasses.The silos are generally provided with means for removing the evolvedgases, and may optionally be provided with means for introducing aninert gas. This inert gas, generally nitrogen, excludes oxygen from thesilos and prevents degradation of the coffee.

One must store the degassing coffee within these silos for as long as isnecessary to evacuate a sufficient amount of gas. For ground coffee, thedegassing time is usually between 30 and 60 minutes for a partialdegassing to 24 hours or more for a full degassing. However duringdegassing, a large part of volatiles aromas of the coffee are lost,diminishing the flavor and the aroma of the coffee beverage.

Of course, degassing of the coffee cannot be totally eliminated betweenthe grinding and the sealing of the capsule since the coffee must betransported from the grinding area to the filling and sealing areas.This “transport degassing” is dependent on the production line capacity.

WO2008129350 refers to a machine for packaging capsules in a vacuumand/or in a controlled atmosphere. After filling with coffee, thecapsules are partially closed by an hermetic film. Then, a vacuum isformed inside the capsules and sealed by a thermo-sealing vacuum device.Optionally, an inert gas can be inserted in the capsule after drawing avacuum to fill the headspace of the capsule with a controlledatmosphere. This invention does not deal with a better preservation ofthe aroma of the packaged product. In particular, there is no indicationthat the degassing of the product is minimized before the capsule ishermetically sealed and gas is kept emanating into the cavity.

In U.S. Pat. No. 3,077,409, the invention seeks to eliminate the holding(degassing) period for coffee before packing it. It so relates to acoffee package with a self-venting reclosure can. The coffee isimmediately filled into the can, thus omitting the conventional holdingcycle. The filled can is then closed under vacuum. The can comprises avalve means permitting a portion of the gas within the container topass. However, the problem of preserving aroma is not tackled since theevolving gas is allowed to escape out of the capsule.

U.S. Pat. No. 4,069,349 refers to a process for vacuum packaging ofroasted ground coffee in pouches. The pouches are partially sealed, witha tortuous unsealed passage, and then stored for a predetermined periodof time to permit the gases to evolve from the pouches and then sealingthe pouches to prevent further gaseous passage to and from the product.The degassing of the product outside the pouch causes the loss ofaromatic compounds.

WO2011039711 relates to a method and machine for packing infusionproduct into capsules; the machine comprising a series of station formanipulating, filling, sealing and overwrapping the capsules and allenclosed within a zone in controlled atmosphere (using nitrogen, forexample) so as to preserve the chemical and physical qualities of theproduct, for example, aroma in the coffee. However, there is noreduction of degassing of the product before sealing and overwrappingthe capsule; no vacuum is drawn in the package before sealing and nodegassing of the product is contemplated in the package to an extentabove the atmospheric pressure. WO2010007633 refers to a machine forpackaging products, in particular capsules for machines for deliveringinfusion beverages. A vacuum bell provides vacuum around each capsule tobe welded. At the same time, vacuum compensating means take care ofinserting gas, in particular nitrogen, inside each capsule in such a wayto compensate the presence of vacuum. Afterwards, the welding means takecare of welding the aluminium sheet onto the edge of the respectivecapsule. Typically, the product must be degassed before closure of thecapsule to prevent over-pressure due to the presence of the compensatinggas. Such degassing causes the loss of volatile aromatic compounds.

Therefore, the presently disclosed and/or claimed inventive concept(s)includes a method for the packaging of a beverage powder tending toevolve a gas in a capsule, in which the flavor and aroma of the beveragepowder are better preserved, that overcome the defects and disadvantagesof the prior art.

BRIEF DESCRIPTION OF THE DRAWINGS

Other particularities and advantages of the presently disclosed and/orclaimed inventive concept(s) will also emerge from the followingdescription.

In the accompanying drawings, given by way of non-limiting examples:

FIG. 1 is a series of orthogonal section views depicting an attachmentmeans, a cutting means, a vacuum-application means, and a sealing meansadapted to perform a method of packaging according to an embodiment ofthe presently disclosed and/or claimed inventive concept(s);

FIG. 2 is a series of orthogonal views of attachment apparatuses in fourdifferent configurations;

FIG. 3 is a flowchart depicting an embodiment of the method of packagingas integrated into a process for the fabrication of beverage capsules;and

FIG. 4 is a schematic view of a method for packaging a capsule in asealing over-packaging according to an alternative embodiment of thepresently disclosed and/or claimed inventive concept(s).

DETAILED DESCRIPTION

The presently disclosed and/or claimed inventive concept(s) relatesgenerally to a method for packaging a beverage powder tending to evolvea gas in a beverage capsule. It also relates to a beverage capsule soproduced. In particular, the presently disclosed and/or claimedinventive concept(s) relates to such capsules as adapted for coffeebeverages.

According to a first aspect, the presently disclosed and/or claimedinventive concept(s) is directed to a method for packaging in a capsulea beverage powder tending to evolve a gas, said capsule comprising acapsule body defining a cavity containing a quantity of beverage powder,said cavity being hermetically sealed up or respectively, the capsulebeing hermetically sealed up by an over-packaging.

The packaging method comprises the following steps: (i) providing aquantity of said beverage powder evolving a gas within said cavity ofsaid capsule body; (ii) applying a vacuum into said cavity of thecapsule body or respectively, into said over-packaging containing thecapsule, so that the internal pressure in the cavity, or respectively,in said over-packaging is below atmospheric pressure; (iii) sealing thecapsule to hermetically close said cavity, or respectively, sealing theover-packaging to hermetically close the over-packaging surrounding thecapsule while maintaining the internal pressure in the cavity, orrespectively, in said over-packaging below atmospheric pressure; and(iv) keeping said gas emanating into the hermetically sealed cavity ofthe capsule so that the internal pressure in the sealed-up capsule, orrespectively, in said over-packaging, is above atmospheric pressure.

This is advantageous in that it permits the packaging of a quantity ofbeverage powder in a capsule after a limited degassing, a furtherdegassing of the coffee instead occurring within the sealed beveragecapsule itself or respectively within the over-packaging sealing-up thecapsule.

According to a principle of the presently disclosed and/or claimedinventive concept(s), the vacuum created within the beverage capsule, orrespectively within the over-packaging, before the capsule orrespectively the over-packaging is sealed, compensates for the pressuregenerated by the gases evolved from the coffee. The accumulation ofevolved gas is thus prevented from building to a pressure that mightcompromise the integrity of the capsule or respectively of theover-packaging.

Since the coffee is not significantly degassed before sealed into thebeverage capsule, the volatile aroma and flavor compounds of thebeverage produced therefrom are preserved and maintained in the capsuleor respectively, in the over-packaging.

In a practical way, when the beverage powder is a ground coffee, themethod comprises a step of grinding coffee beans before the step ofsealing, the duration of a degassing step between grinding the coffeebeans and sealing the cavity, or respectively, sealing theover-packaging is less than 25 minutes, such as but not limited to, lessthan 20 minutes, or comprised between 5 and 15 minutes.

Thus the degassing time is reduced, and in any event, is shorter thanthe duration requested in prior packaging method used to encapsulateground coffee in a hermetically close capsule.

According to a feature, the pressure reduction below atmosphericpressure applied into the cavity, or respectively, into theover-packaging, in the step of applying a vacuum, is comprised between100 and 800 mbar, such as but not limited to, between 250 and 700 mbar,or between 300 and 600 mbar.

These values are well adapted to compensate the increase of pressure inthe capsule body due to the gas evolved by the beverage powder aftersealing of the capsule body.

The atmospheric pressure is the value of the pressure at the locationwhere the step of applying a vacuum occurs.

After the keeping step, the internal pressure is comprised between 1050mbar and 1800 mbar, such as but not limited to, between 1050 and 1600mbar, or between 1050 and 1350 mbar.

The internal pressure is stabilized to a value comprised between 1050mbar and 1800 mbar, such as but not limited to, between 1050 and 1600mbar, or between 1050 and 1350 mbar, about 72 hours after said sealingstep.

This internal pressure is acceptable in term of manufacturing asealed-up capsule and is compatible with a 12 month shelf-life for thebeverage capsules.

According to a second aspect, the presently disclosed and/or claimedinventive concept(s) concerns a beverage capsule comprising a capsulebody defining a cavity and being adapted to be hermetically sealed upwith a quantity of beverage powder provided within said cavity,fabricated by the method of packaging as described above.

The beverage capsule so fabricated will embody the advantages of themethod as detailed above.

According to an advantageous embodiment of the presently disclosedand/or claimed inventive concept(s), the cavity is provided with apredetermined quantity of roast and ground coffee.

In certain particular, non-limiting embodiments, the cavity is providedwith a quantity of roast and ground coffee comprised between 4 and 16grams, such as but not limited to, between 5 and 13 grams. At theequilibrium (after full degassing), the cavity of the capsule has also avolume such as but not limited to, between 8 to 30 ml, or between 10 to20 ml, or between 12 to 16 ml.

The following description will be given with reference to theabove-mentioned figures.

FIG. 1 is a sequence of section views depicting the sealing of abeverage capsule according to the presently disclosed and/or claimedinventive concept(s). FIG. 1 depicts the attachment and cutting steps inviews A through D, and the vacuum application and sealing steps in viewsE through H. Portions of the apparatus are omitted from each of theseviews for purposes of clarity.

View A depicts an attachment means 100 and a cutting means 101 disposedin a first position, prior to the start of an attachment step. Theattachment means 100 and the cutting means 101 are generally tubular andcoaxial about the first longitudinal axis 102.

A capsule body 103 is positioned within the base plate 104, which isprovided with a capsule seat 105 in which the capsule body 103 ispositioned. In certain particular, non-limiting embodiments, the baseplate 104 is configured to be mobile, facilitating a high rate ofproduction of beverage capsules. This mobile configuration may comprisesuch means as a conveyor belt system or rotating turret, for example. Inthe particular, non-limiting embodiment, the capsule body 103 ispositioned beneath the attachment means 100 and cutting means 101 so asto be coaxial with them about the first longitudinal axis 102.

The capsule body 103 defines a cavity 106, in which a predeterminedquantity of roast and ground coffee powder 107 is provided. The capsulebody 103 is substantially cup-shaped, and is provided with an open end108 communicating with said cavity 106. The capsule body 103 is furtherprovided with a flange 109, disposed about the circumference of thecapsule body 103 at the open end 108.

In certain particular, non-limiting embodiments, the capsule body 103 isfabricated from a formable material such as aluminum, plastic, starch,cardboard, or combination thereof. Where the capsule body itself is notgas-impermeable, a gas barrier layer may be incorporated therein toprevent the entry of oxygen. The gas barrier may comprise a coating,film, or layer of a gas-impermeable material such as aluminum, ethylenevinyl alcohol, polyamide, oxides of aluminum or silicon, or combinationsthereof.

For example, in one embodiment, the capsule body 103 is formed ofdeep-drawn aluminum. In another embodiment, the capsule body 103 isformed of deep-drawn polypropylene and aluminum. In a third embodiment,the capsule body 103 is thermoformed from a combination ofpolypropylene, ethylene vinyl alcohol, and polyethylene terephthalate.

In a particular, non-limiting embodiment, the flange 109 and the capsuleseat 105 are configured so that the capsule body 103 protrudes throughthe base plate 104, with the flange 109 resting directly on the baseplate 104 and substantially the entire beverage capsule 103 beingdisposed beneath the base plate 104. In one alternate configuration, thecapsule seat may be configured as a cup, in which the capsule body isseated.

A portion of membrane material 110 is disposed between the cutting means101 and the base plate 104. In certain particular, non-limitingembodiments, said membrane material 110 is provided in the form of acontinuous sheet or web, which may be fed into the apparatus bytechniques adapted from those known in the art of materials handling. Incertain particular, non-limiting embodiments, the membrane material 110is flexible, permitting moderate elastic deformation. The membranematerial 110 may have a thickness between 10 and 250 microns, such asbut not limited to, between 30 and 100 microns.

In a particular, non-limiting embodiment, the membrane material 110comprises at least a base layer fabricated of aluminum, polyester (e.g.PET or PLA), polyolefin(s), polyamide, starch, paper, or any combinationthereof. In certain particular, non-limiting embodiments, the base layeris formed of a laminate comprising two or more sub-layers of thesematerials. The base layer may comprise a sub-layer which acts as a gasbarrier, if none of the other sub-layers are of a material which isimpermeable to gas. The gas barrier sub-layer is fabricated fromaluminum, ethylene vinyl alcohol, polyamide, oxides of aluminum orsilicon, or combinations thereof. In certain particular, non-limitingembodiments, the membrane material 110 also comprises a sealant layer,e.g. polypropylene, disposed to create a seal with the capsule body 103.

For example, in one embodiment the membrane material 110 is an aluminumlayer between 25 and 40 microns. In another embodiment, the membranematerial 110 comprises a base layer with two sub-layers: an externalsub-layer made of PET and an internal sub-layer made of aluminum. Thealuminum sub-layer serves the function of preventing undesirabletransmission of light, moisture, and oxygen. In another embodiment, themembrane material 110 comprises three sub-layers: an external sub-layerof PET 5 to 50 microns thick, a middle sub-layer of aluminum 5 to 20microns thick, and an internal sub-layer of cast polypropylene 5 to 50microns thick.

View B depicts the apparatus in a second position, during a cuttingstep. The cutting means 101 is advanced downward along the firstlongitudinal axis 102 into the membrane material 110. In a particular,non-limiting embodiment, the cutting means 101 is sharpened along itsperipheral edge 111 so as to cut the membrane material 110 when pressedinto it. However, alternate configurations, such as a hot-knifeapparatus, may be preferable for certain compositions of heat-sensitivemembrane material. The cutting means 101 is advanced through themembrane material 110, cutting a membrane 112 of the desired size andshape from the membrane material 110.

View C depicts the apparatus in a third position, during an attachmentstep. At the lower end 113 of the attachment means 100 are disposed aplurality of faces disposed substantially perpendicular to thelongitudinal axis 102, which are pressed into the membrane 112. Theattachment means 100 is advanced so that the lower end 113 presses themembrane 112 into the flange 109 over a plurality of regionscorresponding to the aforementioned faces.

The attachment means 100 is configured to attach the membrane 112 to theflange 109 over the regions where the faces of the lower end 113 presssaid membrane 112 into the flange 109 of the capsule body 103. In thepresent embodiment, the attachment of the membrane 112 to the flange 109of the capsule body 103 is achieved by heat-sealing; though in othernon-limiting embodiments, alternate techniques such as ultrasonicwelding may be preferred.

In certain particular, non-limiting embodiments, the attachment means100 is furnished with appropriate means for attaching the membrane 112to the flange 109 during the attachment step. For example, such meansmay comprise an electrical resistance heater, hot air jet, or ultrasonicwelding horn. This will make the apparatus more compact andspace-efficient.

Said regions of the flange 109 corresponding to the faces of the lowerend 113 of the attachment means 100 will comprise a portion of the totalsurface of the flange 109. The cavity 106 of the capsule body 103thereby remains in communication with the surrounding atmosphere, viathe spaces between the flange 109 and the membrane 112 where themembrane 112 remains unattached to the flange 109.

View D depicts the apparatus in a fourth position, after the completionof the attachment step. The attachment means 100 and cutting means 101are withdrawn from the capsule body 103 and membrane 112. The scrapmembrane material 110 may be removed, while the base plate 104 isadvanced in direction 114 to both place the current beverage capsule inposition for vacuum sealing and bring the next beverage capsule intoposition for the attachment and cutting steps.

In certain particular, non-limiting embodiments, the step for cuttingthe membrane 112 as depicted in View B and the step for attaching saidmembrane 112 to the flange 109 as depicted in View C are performedsequentially but in a continuous movement of descent of the cutting andattachment means 101, 100. A slight vacuum is further applied throughthe attachment means to maintain the membrane 112 in coaxial position inaxis 102 during the cutting and attachment steps. This is advantageous,in that it minimizes the time to fabricate a capsule and thus increasesthe rate at which capsules are produced.

View E depicts the apparatus in a fifth position, prior to the start ofa sealing step. In certain particular, non-limiting embodiments, thevacuum-application means 115 and the sealing means 116 are tubular anddisposed coaxially about the second longitudinal axis 117. The cuttingand attachment means depicted in the previous steps are omitted here forclarity; however, the cutting and attachment means are ideally disposedadjacent or in close proximity to the vacuum-application means 115 andsealing means 116, making the apparatus more compact andspace-efficient.

The base plate 104 is advanced in the direction 114 until the capsulebody 103 and membrane 112 are also coaxial with the vacuum-applicationmeans 115 and the sealing means 116 about the second longitudinal axis117. The capsule body 103 and membrane 112 are thus positioned in acentered position directly below the vacuum-application means 115 andsealing means 116.

View F depicts the apparatus in a sixth position, during avacuum-application step. The vacuum-application means 115 have beenadvanced so as to create an airtight seal between the mouth 118 of thevacuum-application means 115 and the flange 109 of the capsule body 103.A vacuum 119 is applied to the capsule body 103 through thevacuum-application means 115, reducing the pressure in the cavity 106 ofthe capsule body 103 below atmospheric pressure. The gas within thecavity 106 of the capsule body 103 is drawn out through the plurality ofspaces between the flange 109 and the membrane 112, which are defined bythe regions where said membrane 112 remains unattached to said flange109. The gas can be air or any inert gas such as nitrogen, CO₂ or acombination thereof. In this way, the cavity 106 of the capsule body 107is voided of gas without also sucking any of the coffee powder 107 fromthe cavity 106. In this way, the aspiration of the coffee powder intothe apparatus or its entrainment between the flange 109 and membrane 112is avoided.

In certain particular, non-limiting embodiments, the vacuum-applicationstep is configured so that the vacuum may be rapidly applied to thecapsule body 103 while avoiding sucking the coffee powder 107 from thecavity 106. It is known that the rapid application of a vacuum to abeverage capsule may cause some of the coffee powder within to be suckedout, which may result in damage to the apparatus from aspirated coffeepowder. The coffee powder may also become entrained between the sealingsurfaces of the beverage capsule, weakening the seal and diminishing itsaesthetic properties. The application of vacuum may also cause thesealing means to move, further compromising seal integrity.

Here, the attachment of the membrane 112 to the flange 109 of thecapsule body 103 over a plurality of regions will prevents theaspiration and entrainment of the coffee powder 107 between the flange109 and the membrane 112, as well as prevent the displacement of themembrane relative to the capsule body during the application of thevacuum 119. The integrity of the beverage capsule seal and thereliability of the sealing apparatus are thus preserved even when thevacuum is applied very rapidly, permitting higher-quality beveragecapsules to be produced at a faster rate.

In certain particular, non-limiting embodiments, the vacuum-applicationstep is also configured to enable the conditions within the capsule tobe monitored as the vacuum 119 is applied. Specifically, thevacuum-application means permits the rapid application of the vacuum 119to a single capsule body 103, rather than the slower application of avacuum to a group of capsule bodies in a vacuum chamber. Thus, by use ofdata collection and/or control-loop methods known in the art, one maycontinually adapt the parameters of the vacuum-sealing process tooptimize the sealing of each capsule while still maintaining an overallhigh rate of production.

View G depicts the apparatus in a seventh position, during a sealingstep. The mouth 118 of the vacuum-application means 115 is kept incontact with the flange 109 of the capsule body 103, such that thevacuum within the cavity 106 of the capsule body 103 is maintained. Thesealing means 116 is advanced into contact with the membrane 112,pressing into it along the sealing edge 120 disposed at an end of saidsealing means 116. The membrane 112 is pressed into the flange 109 bythe sealing means 116, thereby bonding the remaining unattached regionsof the membrane 112 to the surface of the flange 109 and hermeticallysealing the membrane 112 to the capsule body 103. While the remainingunattached regions of the membrane are bonded, the bond of the attachedregions created during the attachment step may be renewed. The air-tighthermetic seal created between the flange 109 and the membrane 112 willthereby preserve the vacuum in the cavity 106 of the capsule body 103,protecting the coffee powder 107 from exposure to air and subsequentloss of flavor and aroma.

View H depicts the sealed beverage capsule after the completion of thesealing step. The sealing means 116 is withdrawn to allow the bond tosolidify. Then the vacuum is stopped in the vacuum means exposing thecapsule body 103 and membrane 112 to atmospheric pressure and causingthe membrane 112 to take a concave form as depicted. Finally, thevacuum-application means 115 is withdrawn. The vacuum which was appliedto the capsule body 103 in an earlier step is preserved therein by theseal between the flange 109 and the membrane 112. The base plate 104 isthen moved off in direction 114, removing the capsule to be packaged anddistributed and bringing the next capsule into position for vacuumsealing.

Immediately after the completion of the vacuum-sealing step, themembrane 112 will be deflected inwardly into the capsule body 103, aresult of the vacuum within the beverage capsule and exposure to theatmospheric pressure.

As a result of chemical processes triggered by the roasting process, thecoffee powder 107 within the beverage capsule degasses, the gases whichare evolved are kept within the cavity 106 of the beverage capsule bythe membrane 112, the capsule body 103, and the hermetic seal betweenthe two. This accumulation of evolved gases will cause the pressurewithin the beverage capsule to increase until equilibrium pressure isreached. At equilibrium, there will be a positive pressure within thebeverage capsule, i.e. a pressure above the atmospheric pressure,causing the membrane 112 to be deflected outwardly.

The vacuum which is sealed into the beverage capsule thus partiallyoffsets the pressure generated by the gases evolved from the coffeepowder 107. The degree to which the vacuum offsets the evolved gases mayvary from embodiment to embodiment, depending on the volume of thebeverage capsule, the mass of coffee provided within, and the type anddegree of roast of the coffee powder itself. In any case, the vacuumwithin the beverage capsule compensates for the degassing at least tothe extent that the evolved gas is prevented from compromising thestructural integrity of the beverage capsule and its hermeticproperties.

In a particular, non-limiting embodiment, the pressure reduction belowatmospheric pressure is comprised between 100 and 800 mbar, such as butnot limited to, between 250 to 700 mbar or between 300 and 600 mbar.After the beverage capsule is sealed, the gases evolved by the coffeepowder during degassing will continue to accumulate in the cavity 106 ofthe beverage capsule, causing the internal pressure of the beveragecapsule to rise above atmospheric pressure in approximately 5 hours. Incertain particular, non-limiting embodiments, the internal pressure ofthe beverage capsule will reach equilibrium between 1050 and 1800 mbar,such as but not limited to, between 1050 and 1600 mbar, or between 1050and 1350 mbar, in approximately 72 hours after the sealing of thecapsule.

Additionally, the method may be configured so that all, or substantiallyall, of the degassing occurs within the beverage capsule after it hasbeen sealed. While the pressure within the beverage capsule will benegative at time of sealing, the evolved gases will rapidly increase thepressure within the capsules. In a particular, non-limiting embodiment,the capsule will rise above atmospheric pressure in less than 5 hoursand stabilize in approximately 72 hours.

FIG. 2 is a series of orthogonal views depicting a series ofconfigurations for the attachment means. As discussed above, theattachment means comprises at its bottom end a plurality of faces, whichare pressed into the membrane to attach it to the flange of the capsulebody over a plurality of regions corresponding to said faces.

FIG. 2A depicts an attachment means provided with two faces 200 of afirst kind. The faces 200 of a first kind are separated by two channels201 of a first kind. When pressed into a membrane during the attachmentstep as described above, the membrane will be attached to a flange of acapsule body over the portion of the surface of the flange correspondingto the faces 200 of a first kind, while remaining unattached andpermitting fluid communication between the cavity of the capsule bodyand the surrounding atmosphere. Upon the application of a vacuum, theair in the capsule body will flow out through the unattached regionsbetween the membrane and flange defined by the channels 201 of a firstkind.

FIG. 2B depicts an attachment means provided with four faces 202 of asecond kind, separated by four channels 203 of a second kind. Such anattachment means will attach a membrane to a flange of a capsule bodyover a plurality of regions corresponding to each of the four faces 202of a second kind, while leaving the regions of the membranecorresponding to the four channels 203 of a second kind unattached.

FIG. 2C depicts an attachment means provided with eight faces 204 of athird kind, separated by eight channels 205 of a third kind. As above,the faces 204 of a third kind will define the region over which amembrane is attached to the flange of a capsule body, and the channels205 of a third kind defining where it is unattached.

FIG. 2D depicts an attachment means provided with eight faces 206 of afourth kind, separated by eight channels 207 of a fourth kind. Comparedto the attachment means depicted in FIG. 2C, the faces 206 of a fourthkind are much smaller than the faces 204 of a third kind, while thechannels 207 of a fourth kind are much larger than the channels 205 of athird kind. As a result, the proportion of the flange of a capsule bodyto which a membrane will be attached by the attachment device in FIG. 2Dis much lower than would be achieved by the attachment device of FIG.2C, with a corresponding increase in the size of the regions of theflange to which the membrane remains unattached.

The attachment devices may in this way be configured to best suit theparticular application in which the attachment device is to be employed.In the foregoing embodiments the attachment devices are altered byadjusting their number and size; however, in other embodiments it may beadvantageous to modify other elements of their form and geometry such asshape, thickness, or placement about the lower end of the attachmentmeans.

In this way, one may configure the attachment means to reduce the timerequired to apply the vacuum to the capsule body while still minimizingthe aspiration and entrainment of the coffee powder or other ediblegranules contained within the capsule body. The sealing of the beveragecapsules may thus be optimized to achieve a maximum output at a minimumcost.

FIG. 3 is a flowchart depicting the method of packaging as integratedinto a process for the fabrication of beverage capsules, said operationcomprising a series of elements. The first step of the operation isCapsule Body Destacking 300. The empty capsule bodies are generallystored stacked atop each other when stored before use, and so must beseparated before they can be further processed. In the step for CapsuleBody Destacking 300, the capsule bodies are separated from each otherand placed in the proper orientation to continue in the process.

Simultaneously, the Coffee Preparation Process 301 furnishes a supply ofcoffee powder for packaging within the beverage capsules. In the CoffeePreparation Process 301, coffee beans are roasted to the desired degreeof roasting and then ground to the desired degree of fineness.

As discussed above, the gases generated within the coffee beans duringroasting are evolved from the coffee. Some degassing will occur betweenthe roasting of the coffee and the sealing of the beverage capsule. Incertain particular, non-limiting embodiments, it is preferable, however,to configure the process for fabrication of beverage capsules tominimize degassing outside of the capsule, so that the degassingessentially occurs after the beverage capsule has been sealed. In anembodiment, the duration between the grinding of the coffee and thesealing of the capsule is less than ten minutes.

By limiting degassing before sealing, the aroma and flavor in thecapsule are best preserved. After several days, equilibrium is reachedbetween the emanated gases and the retained gases in the coffee. Thisequilibrium depends on the ratio of the coffee weight to the totalvolume in the capsule, the pressure reduction applied during the vacuumstep and the resistance of the capsule to the equilibrium pressure.

Furthermore, since the coffee is not degassed before the sealingprocess, the infrastructure required to degas the coffee beforehand isno longer necessary. This renders the beverage capsule sealing operationmore compact, economical, and flexible.

During Product Filling & Densifying 302, a portion of the coffee powderprovided by the Coffee Preparation Process 301 is placed within thecapsule body and densified, so that the coffee is settled within thecapsule body and the amount of gas therein is so minimized. In analternate embodiment, the beverage powder may be compacted into a tabletduring the Coffee Preparation Process 301 step, which is then positionedin the capsule body during the step of Product Filling & Densifying 302.

Ideally, each element of the operation is linked by a step for Transport303, where the capsule body is transferred between the devices forcarrying out each element of the operation. In addition, it isunderstood that the elements for carrying out each of the elements ofthe process may be located in proximity to each other, or evenintegrated into each other, so that the time required for transportingthe beverage capsule between elements is minimized. The process isthereby rendered more space-efficient and economical.

After this is Membrane Attachment and Cutting 305, as depicted in ViewsA-D of FIG. 1. In this step, the membrane is attached to the flange ofthe capsule body at a plurality of regions of the flange, leaving aplurality of unsealed regions on said flange as well. The membrane isalso cut to a size which will cover the flange and open end of thecapsule body.

Following Membrane Attachment & Cutting 305 is Vacuum Application &Sealing 306, depicted in FIG. 1, Views E-H. A vacuum is applied to thecapsule body, removing the air from within through the plurality ofunsealed regions of the flange. The membrane is then sealed over theentirety of the surface of the flange, preserving the vacuum within thecapsule.

In beverage capsules containing roasted, ground coffee as shown here, itis particularly advantageous that the vacuum within the capsule is areduction of pressure high enough to offset the pressure generated bythe gases evolved by the coffee as it degasses in the capsule. Anormally configured beverage capsule will so resist the pressureaccumulated within the sealed capsule as a result of the evolved gases.

Finally, the capsule is transferred to Distribution 308, where it may bepackaged in a box, sleeve, bag, or the like and distributed for sale.

FIG. 4 depicts a method for packaging a capsule 400 containing beveragepowder tending to evolve a gas, in an over-packaging. The methodcomprises providing a quantity of beverage powder capable of evolving agas within a cavity 406 of a capsule body 403. The capsule body 403 issubstantially cup-shaped and is provided with an open end 408communicating with said cavity and a bottom end 401. The bottom end maybe apertured. For example, a plurality of small apertures can be presentin the wall of the bottom end 401 to facilitate (without need for apuncturing member) the feeding of water and/or discharge of beverageduring extraction. The apertures are small enough to allow liquidtransfer but maintain powder in the cavity.

The capsule 400 may further comprise a flange 409 onto which is sealed alid such as a flexible membrane 412 (Step II). In certain particular,non-limiting embodiments, the membrane material is provided in the formof a continuous sheet or web. In an alternative, the lid can be a rigidor semi-rigid wall member connected to the flange by welding, e.g., heator ultrasonic welding, and/or press-fitting in the cavity. The lid maybe formed of a material hermetical to gas and sealed hermetically on theflange. However, it may also be non-hermetic to gas and liquid. Forexample, the lid may be apertured. A plurality of small apertures can bepresent in the lid to facilitate (without need for a puncturing member)the feeding of water and/or discharge of beverage during extraction. Theapertures are small enough to allow liquid transfer but maintain powderin the cavity.

In this embodiment, the capsule 400 is sealed in an over-packaging 500(Step III). The over-packaging may be a flexible or rigid package. Forexample, it can be a flow wrap package sealed onto a seam 501. A vacuumis drawn before and during sealing of the over-packaging in the interiorof the over-packaging. Since the capsule 400 is permeable to gas, avacuum is formed in the cavity as well. A pressure equilibrium israpidly obtained so that the pressure in the cavity is the same as thepressure between the capsule 400 and the over-packaging 500.

As in the previous embodiment, the gases generated within the coffeebeans during roasting are evolved from the coffee. Some degassing willoccur between the roasting and the sealing of the over-packaging. Incertain particular, non-limiting embodiments, the process is configuredfor fabrication of the packed beverage capsule to minimize degassingbefore sealing, so that the degassing essentially occurs after thebeverage capsule has been sealed in the over-packaging (Step IV). As aresult of the gas emanating in the capsule and traversing the capsule,the pressure in the over-packaging becomes above the atmosphericpressure. In this way the flavor of the coffee is most effectivelypreserved. The over-packaging is essentially impermeable to gas so thatthe evolved gases after sealing is maintained in the over-packaging.After several days, equilibrium is reached between the emanated gasesand the retained gases in the coffee. This equilibrium depends on theratio of the coffee weight to the total volume in the over-packaging,the pressure reduction applied during the vacuum step and the resistanceof the over-packaging to the equilibrium pressure.

In the context as described in the above description, the hermeticalclosure to the gases refers to the ability of the package, that is thecapsule itself or the over-packaging, to maintain an internal pressureabove 1050 mbar for a period of at least one week.

Of course, the presently disclosed and/or claimed inventive concept(s)is not limited to the embodiments described above and in theaccompanying drawings. Modifications remain possible, particularly as tothe construction of the various elements or by substitution of technicalequivalents, without thereby departing from the scope of protection ofthe presently disclosed and/or claimed inventive concept(s).

In particular, it should be understood that the presently disclosedand/or claimed inventive concept(s) may be adapted to fabricate beveragecapsules for the preparation of various kinds of alimentary substances,for example broth, cocoa, coffee, infant formula, milk, tea, tisane orany combination thereof. It should also be understood that the ediblegranules comprising said alimentary substances may be provided invarious forms and sizes, such as flakes, grains, granules, pellets,powders, or shreds and any combinations thereof. While the particularembodiment of the preceding description is directed to a beveragecapsule containing a quantity of roasted, powdered coffee, it should notbe construed as limiting the scope of the presently disclosed and/orclaimed inventive concept(s) to beverage capsules so configured.

The exact configuration and operation of the presently disclosed and/orclaimed inventive concept(s) as practiced may thus vary from theforegoing description without departing from the inventive principledescribed therein. Accordingly, the scope of this disclosure is intendedto be exemplary rather than limiting, and the scope of the presentlydisclosed and/or claimed inventive concept(s) is defined by any claimsthat stem at least in part from it.

1. A method for packaging in a capsule a beverage powder tending toevolve a gas, said capsule comprising a capsule body defining a cavitycontaining a quantity of beverage powder, said cavity being hermeticallysealed up or respectively, the capsule being hermetically sealed up byan over-packaging, the method comprising the steps of: providing aquantity of said beverage powder evolving a gas within said cavity ofsaid capsule body; applying a vacuum into said cavity of the capsulebody, or respectively, into said over-packaging containing the capsule,so that the internal pressure in the cavity, or respectively, in saidover-packaging is below atmospheric pressure; sealing the capsule tohermetically close said cavity, or respectively, sealing theover-packaging to hermetically close the over-packaging surrounding thecapsule while maintaining the internal pressure in the cavity, orrespectively, in said over-packaging below atmospheric pressure; andkeeping said gas emanating into the hermetically closed cavity of thecapsule so that the internal pressure in the sealed-up capsule, orrespectively, in said over-packaging, is above atmospheric pressure. 2.A method according to claim 1, wherein said beverage powder is a groundcoffee, and wherein the method further comprises a step of grindingcoffee beans before said step of sealing, and wherein the duration of adegassing step between grinding the coffee beans and sealing the cavity,or respectively, sealing the over-packaging is less than 25 minutes. 3.A method according to claim 1, wherein the pressure reduction belowatmospheric pressure applied into the cavity, or respectively, into theover-packaging, in the step of applying a vacuum, is comprised between100 and 800 mbar.
 4. A method according to claim 1, wherein after saidkeeping step, the internal pressure is comprised between 1050 mbar and1800 mbar.
 5. A method according to claim 4, wherein said internalpressure is stabilized to a value comprised between 1050 mbar and 1800mbar about 72 hours after said sealing step.
 6. A method according toclaim 1, wherein the capsule is sealed hermetically by sealing amembrane onto the capsule body.
 7. A method according to claim 6,wherein the membrane is sealed onto a flange of the capsule body by heatwelding or ultrasonic sealing.
 8. A method according to claim 1, whereinthe capsule is gas permeable and is contained within said hermeticallysealed over-packaging.
 9. A beverage capsule comprising a capsule bodydefining a cavity and being adapted to be hermetically sealed up with aquantity of beverage powder provided within said cavity, wherein thebeverage capsule is fabricated by the method of packaging according toclaim
 1. 10. A beverage capsule according to claim 9, wherein saidcavity is provided with a predetermined quantity of roast and groundcoffee.
 11. A beverage capsule according to claim 10, wherein saidcavity is provided with a quantity of roast and ground coffee comprisedbetween 4 and 16 grams.
 12. A beverage capsule according to claim 10,wherein at the equilibrium (after full degassing), said cavity has avolume between 8 to 30 ml.